Modular cantilevered shelving assembly and method

ABSTRACT

Some embodiments of the present invention disclose a shelving system having one or more support posts with a plurality of shelf connectors connected to the side of the support post. The connectors can be rigidly secured to the posts and/or can extend through the post and have a portion protruding from both lateral sides of the post. One or more shelves can attach to one or more of the shelf connectors at a variety of heights and extend in a variety of directions with respect tot the support post. These shelves can have a plurality of fingers for connection with laterally-extending support pins mounted to the support posts. Some embodiments also employ shelf brackets having bearing surfaces to distribute load from the shelves tot the vertical support posts.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit and priority of International PatentApplication No. PCT/US2003/011698, filed Apr. 16, 2003, which claimspriority of U.S. Provisional Patent Application No. 60/373,510 filed onApr. 18, 2002.

FIELD OF THE INVENTION

The present invention relates to shelves, racks, and workstations, andmore particularly to shelves, racks, and workstations that arecantilevered for supporting items or for supporting work surfaces.

BACKGROUND OF THE INVENTION

An important function of most shelving and rack systems and workstationsis the ability to increase storage and working space. A number ofimprovements to shelving and rack systems and workstations have improvedthe ability of such structures to perform these functions. However,significant limitations still exist in the design and assembly ofconventional shelving systems, racks and workstations. These limitationsare most apparent in highly competitive industries in which space,assembly and adjustment time, and reliability are at a premium. One suchindustry is the food service industry, where each of these factors playsa significant role in the success and profitability of a business.Therefore, although the present invention (and the problems that existin conventional shelving systems, racks, and workstations referred tobelow) is discussed with reference to the food service industry, itshould be noted that the present invention is applicable to and solvessimilar problems in any industry employing shelving systems, racks, andworkstations. Examples of such industries include retail stores in whichmerchandise is displayed and stored, laboratories and shops wherestorage and work space are needed, and warehouses in which any type ofproduct is organized and stored.

The food service industry is extremely competitive and relies uponefficiency, timeliness and service as cornerstones to distinguishbetween individual food service businesses. Accordingly, increasedresource utilization is a primary goal for most food service businesses,and can significantly impact profitability of such businesses. Forexample, kitchen work space and/or food storage space is an importantresource in the food service industry because of the limited spacetypically available for such purposes. Varying the sizes and layouts ofkitchen and storage space calls for varying types, kinds and sizes ofshelves, racks, and workstations. These structures typically consist ofvertical supports, horizontal storage and support structures, andconnecting elements for connecting the horizontal storage and supportstructures to the vertical supports.

Hereinafter, the term “shelf” or “shelves” refers to any storage andsupport surface used to support product or upon which work can beperformed above ground level. In the food service industry for example,such functions include the storage of food, packaging, cleaning suppliesand equipment, and support for food preparation, cooking, serving, anddishwashing equipment and operations.

In the food service industry, it is normally desirable for shelvingsystems and workstations to be inexpensive, modular, adjustable, easy toassemble and disassemble, easy to clean and reliable. Conventionalshelving systems and workstations do not always satisfy such criteria orprovide the optimal features necessary to accomplish the goals desired.Specifically, many conventional shelving systems and workstations areoften expensive, difficult to clean, assemble, disassemble, and adjust.Also, conventional systems often lack the modularity necessary to meet awide variety of environments or prove to be unreliable.

For obvious reasons, it is an important feature that food serviceshelving systems and workstations be easy to clean. However, manyconventional shelving systems and workstations employ vertical supportposts having a generally C-shaped cross section with one or moreinternal cavities. Because the internal cavities are difficult toaccess, such posts are difficult to clean. In addition, the supportposts of many conventional shelf systems and workstations have slots andother apertures for connecting shelves thereto. These apertures aretypically small, and do not facilitate easy or thorough cleaning ofinterior locations which need to be cleaned.

As mentioned above, the assembly and disassembly of many conventionalshelving systems and workstations is time-consuming and difficult. Thisinefficiency is compounded in many cases in which the shelving systemsand workstations must be frequently moved, requiring the workstations tobe partially or fully assembled and disassembled. Also, manyconventional shelving systems and workstations have shelves constructedof several elements that must be assembled. In many designs, theseshelves include two side brackets, a cross member connecting the sidebrackets, and connecting elements for connecting the shelves to thesupport posts. Assembling and disassembling such shelves can addsignificant time to the overall assembly process.

In many conventional shelving systems and workstations, shelves arewelded or otherwise permanently attached to vertical support posts,making the shelving system or workstation a single integral structure(or defining large subassemblies in such shelving systems andworkstations). This makes the shelving systems and workstations moredifficult to move due to the size and weight of the integral assembliesor subassemblies. Also, by permanently attaching the shelves to supportposts, the shelving systems and workstations can only be arranged in asingle configuration. Other conventional shelving systems andworkstations assemble shelves and support posts by using mechanicalfasteners such as screws, bolts, and pins. Assembling the shelvingsystems and workstations with mechanical fasteners can be difficult andtime consuming, and is often undesirable because tools are needed toproperly assemble the shelving systems and workstations.

Still other conventional shelving systems and workstations include otherconnecting elements for connecting shelves to support posts. Forexample, some shelving systems and workstations employ pins weldedincrementally along the back surface of vertical support posts. Shelvesare mounted to these pins by saddle brackets (brackets that are C-shapedand surround the vertical support posts on the front, side and backsurfaces thereof). Although popular, the use of such saddle bracketsmakes assembly of the shelving systems and workstations difficult for anumber of reasons. Specifically, these saddle brackets must often bemounted on each vertical support post from the side of the shelvingsystem or workstation, which can be a difficult procedure due to tightspace constraints adjacent to the shelving system or workstation.

Many types of conventional shelf brackets (including many saddlebrackets) also present problems and inefficiencies to assemblers of theassociated shelving systems and workstations. In particular, the stepsrequired to assemble the shelves and brackets are often difficult andtime consuming. For example, many brackets (including saddle brackets)are difficult and time consuming to assemble to shelves and to connectto vertical support posts because they provide no immediate visualfeedback to confirm that the brackets have been properly connected tothe vertical support posts. This is because many conventional bracketsconnect to pins extending from the rear surface of the vertical supportposts. Therefore, a person assembling the workstation from the front orthe side cannot see the back surface of the vertical support posts wherethe brackets mount to the pins. In many cases, the assembler mayincorrectly believe that the saddle brackets are properly mounted withthe pins. Because many shelving systems and workstations are large andheavy and are often used to support significant loads, this assemblyerror can result in serious injury and damage to equipment.

Another important issue relevant to shelving systems and workstations isstrength and reliability. Shelving systems and workstations that arestrong, sturdy, and reliable are highly desirable in the food servicebusiness and in any other industry. Unfortunately, however, manyconventional shelving system and workstation designs sacrifice strengthand reliability for other features, including manufacturability,material and costs savings, adjustability, and other features. By way ofexample only, C-channel vertical support posts are commonly used forpurposes of cost and adjustability of elements connected at variouspositions therealong. However, such support posts can be significantlyweaker than support posts having other shapes (e.g., round orrectangular closed tubular support posts).

As another example, the shelves of many conventional shelving systemsand workstations are assembled from multiple elements, which can presentstrength, assembly, and stability issues. In some designs, themultiple-piece shelves typically have two brackets (one bracket mountedto each vertical support post) and a shelf that lies across the brackettops. Improper assembly of the shelf and brackets can cause the shelf tofall or break in use.

Other conventional shelving systems and workstations have shelves thatmount to the vertical support posts by mechanical fasteners such asscrews and bolts. Mechanical fasteners can be unreliable if they are notsufficiently tightened or are improperly tightened, and introduce a fargreater likelihood of assembly error than other manners of mountingshelves.

Still other conventional shelving systems and workstations attempt toaddress this issue by employing pins or posts welded to one surface ofthe vertical support posts and to which shelf brackets can be mounted.However, by welding the pins to only one surface of the vertical supportposts, the entire weight of each shelf is transferred to the weld. Thisconcentration of weight raises undesirable weld stress issues thatreduce the attractiveness of such shelving system and workstationdesigns.

Many conventional shelving systems and workstations have limitedweight-bearing capacity. In some cases, the shelving systems andworkstations are constructed of light gauge shelves and light-gaugevertical support posts that are incapable of supporting large amounts ofweight. Also, some conventional workstations have weak connectors usedto connect shelves to the vertical support posts. Such design featuresrestrict these shelving systems and workstations to light-duty use, andcan limit shelving system and workstation life expectancies.

In light of the problems and limitations of the prior art describedabove, a need exists for shelving systems and workstations that are easyto clean thoroughly, are easy and quick to assemble, provide anadjustable and reliable connection between shelves and vertical supportposts, and can support a relatively large amount of weight. Eachpreferred embodiment of the present invention achieves one or more ofthese results.

SUMMARY OF THE INVENTION

In order to address issues regarding the strength and ease of cleaningof shelving systems and workstations, some embodiments of the presentinvention employ shelf connectors located on, extending through, andpreferably rigidly secured to the vertical supports rather than onlybeing welded to an external face of the vertical supports. These shelfconnectors can take a number of different forms, and in some preferredembodiments are pins. Each pin can have a portion protruding from bothlateral sides of a vertical post. The use of pins on the verticalsupport posts (to which shelf brackets can be attached) results in avertical post design that has no voids or apertures in which dust, dirt,and debris can collect and which provides external surfaces which arerelatively easy to clean.

As discussed above, it is also desirable to have a workstation that iseasy and quick to assemble. In this regard, some preferred embodimentsof the shelving system and workstation according to the presentinvention have shelves that are integral with respect to their bracketsused to attach the shelves to the vertical support posts. These shelvescan have a plurality of fingers for connection with laterally-extendingsupport pins mounted to the vertical support posts. When mounting theshelves to the posts, immediate visual feedback is provided to confirmproper mounting of the fingers to the pins, thereby greatly simplifyingand increasing the reliability of shelving system and workstationassembly.

Some embodiments of the present invention also employ shelf bracketshaving bearing surfaces that can significantly increase the load-bearingcapacity of the shelves and/or can improve the stability of the shelvesand associated shelving systems and workstations. More particularly, theshelves in such embodiments connect to vertical support posts asdescribed above and have bearing surfaces that contact the verticalposts when the shelves are mounted thereto. The bearing surfaces help todistribute load from the shelves to the vertical support posts. Also,weight on the shelves can transmit large torsional forces upon theshelves (such as at the shelf connections with the vertical supportposts). The bearing surfaces described above can reduce the largetorsional forces on the shelf and can help to distribute these forces toincrease the load-bearing capacity of the shelves.

Further objects and advantages of the present invention, together withthe organization and manner of operation thereof, will become apparentfrom the following detailed description of the invention when taken inconjunction with the accompanying drawings, wherein like elements havelike numerals throughout the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described with reference to theaccompanying drawings, which show preferred embodiments of the presentinvention. However, it should be noted that the invention as disclosedin the accompanying drawings is illustrated by way of example only. Thevarious elements and combinations of elements described below andillustrated in the drawings can be arranged and organized differently toresult in embodiments which are still within the spirit and scope of thepresent invention.

In the drawings, wherein like reference numerals indicate like parts:

FIG. 1 is a front perspective view of a workstation according to a firstpreferred embodiment of the present invention;

FIG. 2 is a rear perspective view of the workstation illustrated in FIG.1;

FIG. 3 is a side view of a vertical support post and base illustrated inFIG. 1;

FIG. 4 is a front view of the vertical support post and base illustratedin FIG. 3;

FIG. 5 is a top view of a shelf illustrated in FIG. 1, shown mounted tosectioned vertical support posts;

FIG. 6 is a partial perspective view of the workstation illustrated inFIG. 1;

FIG. 7 is a side view of the shelf illustrated in FIG. 5, shown withoutthe sectioned vertical support posts;

FIG. 8 is a front perspective view of a workstation according to asecond preferred embodiment of the present invention;

FIG. 9 is a detail sectional view of a shelf bracket and supportconnection arrangement according to a third preferred embodiment of thepresent invention;

FIG. 10 is a front perspective view of a workstation according to afourth preferred embodiment of the present invention;

FIG. 11 is a detail sectional view of a shelf bracket and supportconnection arrangement in the workstation illustrated in FIG. 10, takenalong line 11-11 of FIG. 10;

FIG. 12 is a detail sectional view of a shelf bracket and supportconnection arrangement according to a fifth preferred embodiment of thepresent invention;

FIG. 13 is a detail sectional view of a shelf bracket and supportconnection arrangement according to a sixth preferred embodiment of thepresent invention; and

FIG. 14 is a cross-sectional view of an alternative vertical supportpost according to the present invention.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

With reference first to FIGS. 1 and 2, a preferred embodiment of thepresent invention is illustrated with reference to a modular workstation20. Although the structure shown in FIGS. 1 and 2 is a workstation(i.e., providing support for one or more surfaces upon which users canperform work of any kind), it should be noted that the followingdescription of the modular workstation 20 and its alternativeembodiments applies equally to shelving systems, rack systems, and anyother structure which supports surfaces for working or for storing ordisplaying product of any type. Accordingly, the workstations 20illustrated in the figures and described below are presented only by wayof example, and do not indicate that the principles of the presentinvention are limited in applicability to such workstations.

The workstation 20 shown in FIGS. 1 and 2 is suitable for use in anyworkstation environment. As used herein, the term “workstationenvironment” means any location where work is performed on an elevatedsurface. Examples of workstation environments include without limitationrestaurants, fast food outlets, grocery stores, factories, hardwarestores, butcher shops, laboratories, and the like.

The workstation 20 in the illustrated preferred embodiment includesvertical support posts 24 that are vertically erected with respect to aground surface (not shown). Each post 24 includes a cantilevered basemember 28 and an upright member 32 that are generally perpendicular toeach other. The upright member 32 preferably contacts the ground surfaceand extends generally vertically, while the base member 28 preferablyextends from the upright member 32 in a direction generally parallel tothe ground surface. In some embodiments, the base member 28 includes asupport leg 36 that contacts the ground surface a distance from theupright member 32 and provides stability for the post 24. For additionalstrength and stability of the base member 28 and the upright member 32,a gusset 40 can be positioned between the base member 28 and the uprightmember 32 and can be connected to both members 28, 32 in anyconventional manner. Preferably, the posts 24 include a plurality ofsupport pins 44 for mounting items to the posts 24 as will be describedin greater detail below.

Although the posts 24 preferably have base members 28 that are integralwith or connected to the upright members 32, the posts 24 can instead bedefined solely by upright members 32 vertically supported in any othermanner, such as by feet that extend from the bottoms of the posts 24 toprovide an increased footprint of the upright members 32, by beingsecured to other structure behind or adjacent to the upright members 32(such as a wall or framing), and in still other manners. In addition,other relative positions (non-perpendicular) of the base and uprightmembers 28, 32 are possible, as well as other orientations of the basemember 28 with respect to the ground.

If desired, the workstation 20 can be provided with one or morestretchers 48, 52 laterally connecting the upright members 32 together.In the illustrated preferred embodiment for example, the upright members32 are connected together by a lower stretcher 48 and an upper stretcher52. The stretchers 48, 52 can be connected to the upright members 32 inany manner, such as by bolts, screws, rivets, pins, clips, and otherconventional fasteners 56, by fingers, headed posts, hooks, or otherextensions of the stretchers 48, 52 extending into mating connectors orapertures in the upright members 32 (and vice versa), or in any othermanner desired. For example, the upper stretcher 52 in the illustratedpreferred embodiment is mounted to the posts 24 by way of the supportpins 44 as will be described in greater detail below. Although the lowerand upper stretchers 48, 52 have been described with the above-notedmounting positions and mounting elements, any number of stretchers 48,52 (and in some cases, even no stretchers) can be connected to theupright members 32 at any location(s) along the upright members 32 inorder to connect the upright members 32 together.

If desired, the workstation 20 can include any number of additionalframe members extending between and connecting the upright members 32for further support, including without limitation cross supports 60coupled to and extending diagonally between the upright members 32. Twosuch supports 60 are shown in FIGS. 1 and 2. The cross supports 60 canbe connected to the upright members 32 in any conventional manner,including those mentioned above with regard to the connection of thelower and upper stretchers 48, 52 to the upright members 32. Preferably,opposite ends of each cross support 60 are connected to the uprightmembers 32.

FIGS. 3 and 4 provide additional views of one of the posts shown inFIGS. 1 and 2. In this preferred embodiment, support pins 44 are mountedincrementally along the upright member 32 of the post 24. The supportpins 44 can be mounted at any regular or irregular distance from oneanother along any length or lengths of the post 24. However, in somepreferred embodiments, the support pins 44 are mounted at regularintervals along the majority of the post's length. Preferably, thesupport pins 44 are mounted between 1″ and 4″ apart (measured from pincenter-to-center). More preferably, the support pins 44 are mountedbetween 2″ and 4″ apart. However, the inventors have found that abalance between excellent shelf adjustability and mounting strengthresults from support pins 44 mounted at 2″ intervals along part or allof the length of the post 24.

The pins 44 can take any shape desired, such as pins having a round orsubstantially round cross-sectional shape as illustrated in the figures,a rectangular cross-sectional shape, an irregular cross-sectional shape,and the like. In addition, the pins 44 can have any size and diameterdesired. In some embodiments, the pins 44 have a round cross-sectionalshape and are approximately 5/16″ (0.3125″) in diameter.

The pins 44 preferably extend laterally through the posts 24 as shown inFIGS. 1-4. Specifically, each pin 44 is preferably a single piece thatextends laterally through the post 24 and has a portion of the pin 44protruding laterally from both sides 68, 70 of the post 24 (i.e.,protruding from the left and right side surfaces 68, 70 of the post 24with respect to a viewing position in front of and facing theworkstation 20). Preferably, each pin 44 is welded to the post 24 on theleft side surface 68 or the right side surface 72. More preferably, eachpin 44 is welded to the post 24 on both the left and right side surfaces68, 72 of the post 24. Although the pins 44 are preferably welded toboth lateral sides 68, 72 of the post 24, it should be noted that pins44 extending through and past both sides 68, 72 of the post 24 can besecured to the post 24 in a number of other manners, including withoutlimitation by being press-fit or by otherwise having an interference fitwithin apertures on both sides 68, 72 of the post 24, by being fastenedto the post 24 with one or more fasteners (e.g., cotter pins, setscrews,or other fasteners extending through at least part of each pin 44 onopposite sides of the post 24 to prevent removal of the pins 44), bybeing threaded into a threaded aperture extending through the post 24,by a snap-fit into the side apertures 68, 72 of the post, by a keyed orinter-engaging connection between the pins 44 and side walls 68, 70(e.g., one or more teeth, fingers, or other protrusions in the sideapertures 68, 72 mating with one or more grooves, slits, or otherapertures in the pins 44, and vice versa), and the like. One havingordinary skill in the art will appreciate that the pins 44 can besecured in the post 24 in a number of other manners, each one of whichfalls within the spirit and scope of the present invention. Preferablyhowever, the engagement of the pins 44 leaves no externally-exposedcavities or other apertures that would otherwise make cleaning of theworkstation 20 difficult.

Although pins 44 extending through the posts 24 as described above aremost preferred for reasons of strength and reliability, otherembodiments of the present invention employs pins 44 that are secured toeither or both sides 68, 72 of the posts 24 rather than pins 44extending through the posts 24. In such embodiments, the pins 44 can besecured to the posts 24 in any manner desired, including those describedabove with reference to the pins 44 in the preferred embodimentsillustrated in the figures. Most preferably however, pins 44 secured toeither or both sides 68, 72 of the posts 24 are welded to the posts 24.

With continued reference to FIGS. 1 and 2, the workstation 20 preferablyincludes one or more shelves 64 having any size desired. In somepreferred embodiments (including those shown in the figures), theshelves 64 are mounted to the posts 24 by way of the support pins 44 aswill be discussed below.

A preferred embodiment of a shelf 64 used in the workstation 20 of thepresent invention is illustrated in FIGS. 5-7. However, it should benoted that other shelves 64 having different sizes and shapes can employthe same features described hereafter. In some preferred embodiments,the shelf 64 is a single integral piece having one or more cross members76 and side brackets 80. The cross members 76 preferably extend betweenthe side brackets 80 and provide a support surface for the shelf.Alternatively, the side brackets 80 can be connected by a frame, sheet,series of bars or poles, mesh, screen, or any other element extendingbetween the side brackets 80 for purposes of supporting weight, forsupporting surface covers upon which to work or store and displayarticles, and/or for securing the side brackets 80 with respect to oneanother. In some embodiments, the side brackets 80 are connected by oneor more cross members 77 near a location where the shelf is mounted tothe support posts 24. Such a cross member 77 is illustrated in FIG. 1 byway of example only.

As an alternative to cross members 76 that are integral with the sidebrackets 80 (such as by welding, soldering, brazing, or by beingstamped, pressed, bent, extruded, molded, cast, or otherwise formed outof a single element), the cross members 76 can be assembled to the sidebrackets 80 in a number of different manners. For example, the crossmembers 76 can be connected to the side brackets 80 with fingers,screws, pins, inter-engaging elements, or in any other manner desired,including those described above with reference to the connections of thestretchers 48, 52 to the upright members 32.

Preferably, each side bracket 80 includes or defines a flange 84 towhich the cross members 76 are connected. Although any orientationbetween the flange 84 and posts 24 can exist, the flange 84 ispreferably generally perpendicular to the plane shared by the posts 24.Depending at least partially upon the manner in which the flanges 84 areconnected to the upright members (as will be described in greater detailbelow), the flanges 84 can extend from the posts 24 at any relativeangle with respect to the posts 24. In the illustrated embodiment and insome other preferred embodiments, the flanges 84 extend generally awayfrom a centerline 88 of the posts 24.

Some preferred embodiments of the flanges 84 are shaped to contact andbear against a surface of the upright members 32. In these embodiments,the brackets 80 preferably include bearing surfaces 92 that aregenerally perpendicular to the flanges 84 and are generally parallel toa front surface 96 of the upright members 32. In such embodiments, eachbearing surface 92 preferably extends laterally from the end of theflange 84 toward either side wall 68, 70 of the upright members 32 (ortoward both side walls 68, 70). However, with respect to a workstation20 having upright members 32 supporting ends of shelves 64 connectedthereto (see FIGS. 1 and 2), the bearing surface 92 preferably extendslaterally inward (in a direction toward the other upright member 32 andbracket 80).

The bearing surface 92 can extend across any part of the front surface96 of the upright members 32, such as laterally from one side wall 68 ofthe upright member 32 to the other 70, or laterally across any portionof the width of the front surface 96. In the illustrated preferredembodiment, the bearing surface 92 extends laterally from the midpointor centerline 88 of the upright member 32 to the inside wall 68 of theupright member 32. In each flange embodiment having a bearing surface asjust described, when the shelf 64 is mounted to a post 24, the bearingsurface 92 contacts a wall (e.g., a front surface 96) of the post 24 andthereby prevents torsional rotation of the shelf 64. Torsional rotationof the shelf 64 is typically created by the weight of the shelf 64 andby placing weight upon the shelf 64. The more weight that is placed uponthe shelf 64, the larger the torsional forces that will be exerted uponthe shelf 64. Torsional forces created from the weight of the shelf 64and from weight upon the shelf 64 can be better supported bydistributing the forces to a wall of the upright members 32 via thebearing surfaces 92. In this regard, forces are preferably distributedacross part or all of the bearing surface 92 by virtue of the shape ofthe shelf flanges 84. In the illustrated preferred embodiment, theseupright member walls are the front walls 96 of the upright members 32.

Each bracket 80 preferably also extends at least partially along a sideof an upright member 32 and for connection thereto. This manner ofconnection can take any number of forms, including without limitationone or more pins, headed posts, teeth, fingers, or other protrusions onthe bracket 80 extending into one or more apertures in the uprightmember 32 (and vice versa), inter-engaging elements or features of thebracket 80 and the upright member 32, by one or more bolts, screws, orother fasteners, and the like. In some highly preferred embodimentshowever, the brackets 80 include a plurality of rearwardly-extendingfingers or hooks 100 that curve downward to define a plurality ofcavities 104 that open upward. The fingers or hooks 100 can be spaced atany regular or irregular intervals. For example, in the illustratedpreferred embodiment, the hooks 100 are spaced from each other on 1″centers. The hooks 100 and openings 104 preferably work collectively toform spaces to receive and secure the pins 44 of the upright members 32(described above) to mount the shelf 64 to the posts 24 and to preventvertical or downward movement of the shelf 64. In this regard, the hooks100 and openings 104 of the brackets 80 receive and hold portions of thepins 44 protruding from the surfaces of the posts 24.

The shelf 64 is preferably mounted to the posts 24 by positioning theshelf 64 in front of the posts 24 at the desired height of the shelf 64.With reference to the illustrated preferred embodiments shown in thefigures, the hooks 100 on the brackets 80 are positioned between theinside surfaces 68 of the posts 24—that is, the hooks 100 are inboard ofthe posts 24. In alternative embodiments however, the flanges 84 can beshaped so that the hooks 100 on the brackets 80 are positioned on theoutboard surfaces 70 of the posts 24. Next, the shelf 64 is preferablymoved toward the posts 24, such that the hooks 100 move between theposts 24 (or on the outboard sides of the posts 24 in the alternativeembodiments just mentioned), and the bearing surfaces 92 contact thefront surfaces 96 of the posts 24. The pins 44 preferably slide throughslots 108 beneath the hooks 100 and contact the brackets 80 below theopenings 104. The shelf 64 can then be moved downward until the pins 44slide into the openings 104 and contact the hooks 100. At this time, theshelf 64 is locked in place and cannot move or rotate downward (forreasons discussed above).

The procedure for mounting the shelves 64 discussed above is veryreliable. By mounting the shelves 64 according to this procedure,immediate visual feedback is provided to confirm proper mounting of thehooks 100 to the pins 44. The immediate visual feedback is enabled bythe connections of the brackets 80 to the sides of the uprights 32rather than to the rear of the uprights 32 as is found in the prior art.This greatly decreases the chance of the shelf 64 being mountedimproperly and causing injury and/or damaged equipment.

If desired, the shelves 64 can be provided with shelf covers (not shown)that can rest upon and/or can be connected to the top of the shelves 64in any conventional manner. In some embodiments, the shelf coversprovide a flat support surface and working surface (rather than thecross members 76). The shelf covers can come in a variety of shapes,sizes and materials depending upon the application of the workstation20.

Referring to FIGS. 8 and 9, some embodiments of the workstation 20according to the present invention provide improved modularity byenabling shelves 64 to be connected to vertical support posts 24 oneither or both sides 68, 72 of the posts 24. Even greater modularity ispossible by enabling shelves 64 to be connected in this manner at thesame height on the support posts 24, in which case two shelves onopposite sides 68, 72 of the same support post 24 can utilize the samepins 44 for connection to the post 24.

As discussed above, the flanges 84 of the shelves 64 in a number ofpreferred embodiments extend generally away from the centerline 88 ofthe posts 24. Therefore, by mounting shelves 64 on opposite sides 68, 72of the same post 24 as just described, the flanges 84 on the two shelves64 can extend generally adjacent to one another from the centerline ofthe post 24. In some cases, two adjacent shelves as described above cantherefore be mounted to the same post 24 to define a substantiallycontinuous shelf. Therefore, the shelves 64 and flanges 84 can havelittle to no gap therebetween, resulting in a substantial space savingswhen compared to conventional systems in which a gap exists betweenadjacent shelves and shelf brackets. Also, conventional workstationscommonly employ vertical support posts that can only support shelves onone side of the vertical support posts. If another shelf is desiredadjacent to and at the same height as the first shelf in suchworkstations, a second vertical support post is needed beside the firstvertical support post. Therefore, existing workstations typicallyrequire several more vertical support posts than the present invention,have a gap between adjacent shelves, and occupy a larger footprint as aresult of the additional vertical support posts.

FIGS. 10 and 11 illustrate an alternative embodiment of the presentinvention in which posts 24 support shelves 64 mounted to the inside andoutside surfaces 68, 72 of the posts 24 (similar to the workstationillustrated in FIGS. 8 and 9). However, FIGS. 10 and 11 also show howshelves 64 can be connected to the posts 24 to face in oppositedirections. As illustrated in FIGS. 10 and 11, the shelves 64 can evenemploy the same pins 44 on the posts 24 in such configurations.

Referring to FIG. 12, some embodiments of the workstation 20 accordingto the present invention include shelves 64 that can extend from boththe front surface 96 of the post 24 and a rear surface 112 of the post24. Therefore, the workstation 20 has forward and rearwardly-facingshelves 64. The side brackets 80 in such embodiments can take any formdiscussed above with reference to the earlier-described embodiments. InFIG. 12 for example, both side brackets 80 have flanges 84 that extendaway from centerline 88 running along the post 24. Each side bracket 80in the illustrated preferred embodiment has two bearing surfaces 92: onethat contacts the front surface 96 and one that contacts the rearsurface 112 to distribute torsional force upon the shelves 64 asdescribed earlier.

Referring to FIG. 13, some embodiments of the workstation 20 accordingto the present invention include shelves 64 with different types ofbrackets 80 that can be mounted to the same post 24. For example, abracket 80 can be employed that cups a side of the post 24 and extendsaway from opposite sides of the support post 24 at front and rearcenterlines running along the post 24 (similar to the brackets 80described above and illustrated in FIG. 12). This bracket 80 can sharethe same support post 24 as a second bracket connected to an oppositeside of the support post 24 and that extends away from only one of thecenterlines running along the post 24. Because both types of sidebrackets 80 have flanges 84 that extend generally from the centerlines88 of the post 24 a substantial gap is not created between the sidebrackets 80.

Referring to FIG. 14, some embodiments of the workstation 20 accordingto the present invention employ pins 116 incrementally mounted to eachof the inside and outside surfaces 68, 72 of the support posts 24. Theshelves 64 can mount to the pins 116 in similar fashions as discussed inthe above embodiments. Preferably, the pins 116 are welded to thesupport posts 24. However, the pins 116 can be mounted to the supportposts 24 in any other manner as desired. For example, the pins 116 canbe mounted to the support posts 24 by friction fitting, fasteners or akeyed connection.

By employing the vertical post, shelf, and bracket structure describedabove, a number of embodiments of the present invention provide aworkstation (or a shelving or rack system) that is highly adjustable,modular, and adaptable to a large number of applications, spaces, andenvironments. In the various embodiments described above and illustratedin the figures, the use of support posts 24 having pins 44 on oppositesides thereof enables a user to mount shelves 64 on both sides of theposts 24 and to share the same posts 24 with shelves 64 located inadjacent units. In addition, various embodiments of the presentinvention enable the user to assemble the workstation 20 (or shelving orrack system) as a wall unit, as a free-standing unit with shelves 64accessible from multiple positions around the workstation 20, and/or asa modular system having multiple side-by-side shelf units with a reducednumber of support posts 24 and a smaller footprint. This versatility,coupled with the more reliable and simpler shelf mounting arrangement ofthe present invention, provides a number of advantages as discussedabove.

The embodiments described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the present invention. As such, itwill be appreciated by one having ordinary skill in the art that variouschanges in the elements and their configuration and arrangement arepossible without departing from the spirit and scope of the presentinvention. For example (and as described in greater detail above),rather than employ side brackets 80 of two separate shelves 64 extendingfrom the posts 24 in the same direction, the side brackets 80 from thetwo separate shelves 64 can extend in opposite directions to give theworkstation 20 greater modularity and greater freedom to accommodateparticular user needs and preferences. As another example (and as alsodescribed above) the vertical support posts 24 can include a pluralityof pins 116 incrementally mounted to each of the inside and outsidesurfaces 68, 72 of the support posts 24.

As yet another example, the various elements of the modular workstations20 are illustrated in the accompanying figures with exemplary shapes.However, these shapes can be different in alternative embodiments of thepresent invention. By way of example only, the upright members 32illustrated in the accompanying figures have rectangular cross-sectionalshapes (i.e., having readily identifiable front, rear, and lateral sideswith respect to the front, rear, and sides of the modular workstations20), and in some embodiments are defined by 1″ tube stock. However, theupright members 32 need not necessarily have rectangular cross-sectionalshapes. The upright members 32 can have any other cross-sectional shapedesired, including without limitation round and irregularcross-sectional shapes. In this regard, it should be noted that theupright members 32 of in the various embodiments of the presentinvention still have identifiable front, rear, and lateralsides—regardless of the shape of the upright members 32. Therefore, asused herein and in the appended claims, when a support post or uprightmember is referred to as having “sides” this is not intended as alimitation on the cross sectional shape of the support post or uprightmember. Terms such as “front”, “back”, and “side” are used herein inorder to indicate a general area or surface of the support post orupright member. For example, a post with a circular cross-sectionalshape can have sides as well as a front and a back even though separatewalls defined by corners do not exist.

1. A cantilevered shelf releasably connectable to first and second postsat a plurality of different heights along the first and second posts,each post having a front, a rear, and opposed sides, the cantileveredshelf comprising: a first flange having an end releasably engagable withan exterior surface of one of the opposing sides of the first post, thefirst flange shaped to extend across less than an entire front width ofthe first post measured in a lateral direction of the first post todefine a bearing surface of the first flange abutting the front of thefirst post; a second flange having an end releasably engagable with anexterior surface of one of the opposing sides of the second post, thesecond flange shaped to extend across less than an entire front width ofthe second post measured in a lateral direction of the second post todefine a bearing surface of the second flange abutting the front of thesecond post; and a shelf body attached to and extending between thefirst flange and the second flange; wherein the first and second postsfurther comprise a plurality of connectors extending laterally and awayfrom the opposed sides of the posts, the ends of the first and secondflanges releasably engagable with at least one connector on the firstand second posts, respectively, at different heights along the first andsecond posts defined at least in part by the locations of the pluralityof connectors on the posts, said connectors passing through the endportions of the first and second flanges.
 2. The shelf as claimed inclaim 1, further comprising a shelf cover attached to the shelf body. 3.The shelf as claimed in claim 1, wherein the shelf body has a surfaceupon which items supported by the shelf rest.
 4. The shelf as claimed inclaim 1, wherein the plurality of connectors are pins extendinglaterally and away from the opposed sides of the first and second posts.5. The shelf as claimed in claim 4, wherein the pins extend through thefirst and second posts.